Storage Propane

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UnitedStates OfficeofSolidWaste EPA550-B-00-001EnvironmentalProtection and March2009Agency EmergencyResponse www.epa.gov/emergencies

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Office

of

Emergency

Management


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This document provides guidance to owners and operators of stationary sources to determine if their

processes are subject to regulation under section 112(r) of the Clean Air Act and 40 CFR part 68 and to

comply with regulations. This document does not substitute for EPAs regulations, nor is it a regulation

itself. Thus, it cannot impose legally binding requirements on EPA, states, or the regulated community,

and may not apply to a particular situation based upon circumstances. This guidance does not represent

final agency action, and EPA may change it in the future, as appropriate.


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TABLE OF CONTENTS

INTRODUCTION

1

Am I Covered? 1

What Do I Have To Do? 2

PROGRAM 1 5

Eligibility 5

What Must I Do For A Program 1 Process? 6

PROGRAM 3 9

What Must I Do For A Program 3 Process? 9

What Are The Release Scenarios? 9

What Do I Have To Do For The Prevention Program? 10What Do I Have To Do For The Emergency Response Program? 15

What Do I Have To Do For My RMP? 15

SAMPLE RMP FOR PROGRAM 1 STORAGE FACILITY 17

SAMPLE RMP FOR PROGRAM 3 STORAGE FACILITY 23

APPENDIX A: HOW DO I DETERMINE IF MY SEPARATE (NON-

INTERCONNECTED) PROPANE TANKS ARE CO-LOCATED

APPENDIX B: RELEASE CALCULATIONS

APPENDIX C: CHECKLISTS AND OTHER DOCUMENTS

Process Safety Information

Propane Storage Facility Checklist

Operating Procedure Requirements

Maintenance Training

Maintenance Inspection Checklist and Tests for Propane Storage Facilities

LIST OF TABLES

Table 1: Typical Water Capacity of Propane Tanks, Transports, and Railroad Tank Cars

Table 2: Distance to a 1 PSI OverpressureTable 3: Distances to 1 PSI for Pipe Releases

Table 4: Ways to Comply with Some Prevention Elements


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TABLE OF POTENTIALLY REGULATED ENTITIES

This table is not intended to be exhaustive, but rather provides a guide for readers

regarding entities likely to be regulated under 40 CFR part 68. This table lists

the types of entities that EPA is now aware could potentially be regulated by thisrule and covered by this document. Other types of entities not listed in this table

could also be affected. To determine whether your facility is covered by the risk

management program rules in part 68, you should carefully examine the

applicability criteria discussed in Chapter 1 of this guidance and in 40 CFR

68.10. If you have questions regarding the applicability of this rule to a

particular entity, call the EPCRA/CAA Hotline at (800) 424-9346 (TDD: (800)

553-7672).

Category NAICS

Codes

SIC

Codes

Examples of Potentially Regulated

Entities

Propane

manufacturers and

processors

32411

32511

2911

2865

2869

Petroleum refineries

Petrochemical Manufacturers

Propane wholesalers 42271

42272

5171

5172

Bulk stations and terminals

Other petroleum product wholesalers


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INTRODUCTION

This guidance is intended for propane storage facilities, such as wholesale distribution facilities and bulk

storage terminals. This document is a revision of EPAs October 1998 guidance for propane storagefacilities. The document has been revised to reflect changes resulting from the 1999 Chemical Safety

Information, Site Security and Fuels Regulatory Relief Act.

If you have more than 10,000 pounds of propane stored in a single vessel or in a group of vessels (tanks,

cylinders) that are connected or stored close together, you may need to comply with the Chemical

Accident Prevention rule issued by the U.S. Environmental Protection Agency (EPA) under the Clean

Air Act. The rule is codified as part 68 of Title 40 of the Code of Federal Regulations (CFR). The goal

of this rule is to prevent accidental releases that could affect the public or the environment. If you are

subject to part 68 for propane storage, you must be in compliance no later than January 5, 2000, or the

date on which you first have more than a threshold quantity of a regulated substance in a process,

whichever is later.

If you have more than 10,000 pounds of propane, you are subject to part 68 unless one of the following

applies to you:

The propane is stored for use as a fuel at your facility.

The propane is held for sale, and the facility is a retail facility. A retail facility is one at which

more than half of the income is obtained from direct sales to end users or at which more than half

the fuel sold, by volume, is sold through a cylinder exchange program.

If you have more than 10,000 pounds of propane and you manufacture propane, use it as a feedstock, or

store it in bulk for sale, other than to end users, or if your retail sales do not make up more than half of

your income, you are subject to part 68. If you manufacture or use propane as a feedstock or store it for

wholesale distribution and use it as a fuel, the propane used for fuel is not covered by part 68; thepropane manufactured, processed, or stored for wholesale distribution is subject to part 68 provided the

quantity is greater than 10,000 pounds. If you use propane to fuel a covered process containing other

regulated substances above their thresholds, the propane is not covered, but you will have to consider the

hazards created by the propane when you conduct your process hazard analysis or hazard review.

For most propane storage facilities, complying with this rule will be easy because most of the

requirements are similar to those you already comply with under state or local rules based on the

National Fire Protection Association (NFPA) standard number 58 on propane. If you are complying with

NFPA-58 and implementing other safe engineering practices for propane, you should have little more to

do for this rule besides filing a report with EPA.

AM I COVERED?

The capacity of propane tanks is usually given as water capacity (this information should be on the

nameplate of the tank). Table 1 translates the water capacity (in gallons) into propane weight (in

pounds). Read the tank capacity on the nameplate and check this table.

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Table 1 assumes that tanks are filled to 88 percent of capacity, the maximum level allowable under

NFPA-58 at 60 F. If you always keep your tanks filled to a lower level, you should adjust these numbers

to reflect your lower inventory. If you have larger tanks, multiply the water capacity times 3.696 to

determine pounds at 88 percent capacity.

TABLE 1

TYPICAL WATER CAPACITY OF PROPANE TANKS,

TRANSPORTS AND RAILROAD TANK CARS

Capacity in Gallons Capacity in Pounds

Storage Tank 12,000 44,400





Storage Tank 100,000 370,000

Storage Tank 120,000 444,000

Transport (Cargo Tank) 8,000 - 11,000 30,000-41,000

Rail Car DOT Class 105J300W & 105A300W 11,000 - 34,500 41,000-128,000

Rail Car DOT Class 112J340W & 112T340W

114J340W & 114T340W

114J400W & 114T400W

26,000 - 34,500 96,000-128,000

Bobtails (Delivery Cargo Tank) 750 - 3200 2,800-12,000

Also, add up the amounts of propane in tanks that are connected or close together. If you have four 750

gallon tanks, you are subject to the rule if the tanks are connected by piping, or if you store the tanks

close enough together that they could be involved in a single accident. For example, if a fire could

spread to all the tanks, they are considered one process, and the propane in all the tanks must be

counted toward the 10,000-pound threshold. You should also consider whether, if one tank exploded, the

other tanks could be affected by the shrapnel or fire. If you have several groups of propane tanks, widely

separated, you may be considered to have multiple processes (see Appendix A for additional guidance on

determining whether your propane tanks are separated far enough to be considered multiple processes.)

WHAT DO I HAVE TO DO?

The first step you should take after determining that you are covered by the rule is to decide which

Program level you are in. EPA developed the rule with three Program levels to reflect different levels of

risk and levels of effort needed to prevent accidents.

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Program 1 is a minimal set of requirements for processes that have a very low risk of affecting

the public in the event of an accident.

Program 2is a streamlined set of requirements for processes not eligible for Program 1 or

subject to Program 3.

Program 3applies to processes that are not eligible for Program 1 and that are either subject to

the Process Safety Management (PSM) Standard of the Occupational Safety and Health

Administration (OSHA) or in certain industrial sectors (some chemical manufacturers, all

refineries, and all pulp mills).

This document does not provide detailed guidance on Program 3. Propane storage facilities subject to

part 68 will generally either be eligible for Program 1 or subject to Program 3. The OSHA PSM standard

exempts all retail facilities, using the same definition of retail facilities given above, and fuel users, but

covers wholesalers and manufacturers that process propane. Consequently, a propane facility subject to

part 68 will generally also be subject to the OSHA PSM standard. If you are subject to the OSHA PSM

standard, you should also see EPAs General Guidance for Risk Management Programsor OSHAs

Process Safety Management Guidelines for Compliance(OSHA 3133).

If you can qualify a process for Program 1, it is in your best interests to do so, even if the process is

already subject to OSHA PSM. For Program 1 processes, the implementing agency will enforce only the

minimal Program 1 requirements. If you assign a process to Program 3 when it might qualify for

Program 1, the implementing agency will enforce all of the requirements of the higher program level. If,

however, you are already in compliance with the prevention elements of Program 3, you may want to use

your RMP to inform the community of your prevention efforts.

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PROGRAM 1

ELIGIBILITY

Some propane storage facilities will be eligible for Program 1, particularly those that are a considerable

distance from any other business or residence. For a process to be eligible for Program 1, it must meet

the following criteria:

The process must not have had an accidental release of propane that led to deaths or injuries of

people offsite or response or restoration activities at environmental receptors in the last five

years. Environmental receptors are limited to national or state parks, forests, or monuments;

officially designated wildlife sanctuaries, preserves, refuges, or areas; and Federal wilderness

areas; and,

There are no public receptors within a distance to a 1 psi overpressure from a worst-case release.

A worst-case release is defined by the rule as the loss of the contents of the single largest vessel (or

piping) containing the regulated substance. For propane and other flammable substances, the released

substance is assumed to explode and generate a pressure wave that can damage people or structures. The

rule requires you to determine the distance to a 1 psi overpressure (at 1 psi, windows will break). This

scenario is required by the regulation, and you must adopt this scenario. Table 2 provides the worst-case

distance to a 1 psi overpressure for propane tanks.

TABLE 2

DISTANCE TO A 1 PSI OVERPRESSURE

Nominal Water Capacity

(Gallons)

Distance to Endpoint

(Miles)

500 - 1,750 0.1

1,751 - 7,000 0.2

7,001 - 23,000 0.3

23,001 - 51,000 0.4

51,001 - 90,000 0.5

90,001 - 120,000 0.6

If you have different quantities, RMP*Comp, a software system developed by EPA and NOAA, will

allow you to calculate worst-case distances quickly. RMP*Comp can be downloaded from

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www.epa.gov/emergencies/rmp. You may also use other models to develop distance estimates (see 40

CFR 68.22 for the parameters you must use in estimating worst-case release distances). Next, you must

determine if there are public receptors within a circle whose radius is equal to this distance. Public

receptors include offsite residences, institutions (e.g., schools and hospitals), industrial, commercial, and

office buildings, parks, or recreational areas inhabited or occupied by the public at any time without

restriction by the stationary source where members of the public could be exposed to toxic concentrations,

radiant heat, or overpressure, as a result of an accidental release. Offsite means areas beyond yourproperty boundary and "areas within the property boundary to which the public has routine and

unrestricted access during or outside business hours." Public roads are not public receptors.

If there are no public receptors within the distance to a 1 psi overpressure for your largest vessel and the

process has not had an accidental release that caused any of the listed offsite impacts, your process is

eligible for Program 1. If you have questions about whether certain areas are considered public receptors,

call the Emergency Planning and Community Right-to-Know Act (EPCRA) hotline at (800) 424-9346(for DC area (703) 412-9810; T.D. (800) 553-7672) or check EPAs General Guidance for Risk

Management Programs (available from the hotline or electronically at www.epa.gov/emergencies/rmp).

WHAT MUST I DO FOR A PROGRAM 1 PROCESS?

Because your worst-case release would not affect public receptors, you only need to do two things:

Coordinate emergency response with your local fire department and any other local emergency

planning and response agencies; and,

Complete a brief Risk Management Plan (RMP), as described below

Coordination with the fire department may consist of a discussion with them or a walk-through of your

facility. The purpose is simply to be sure that the fire department is aware of the hazards associated with

propane at your facility and ready to respond if an accident occurs. Also, contact your State Emergency

Response Commission (SERC) to identify your Local Emergency Planning Committee (LEPC). You can

get contact information for your SERC from the EPCRA hotline (noted above).

The RMP will be filed with EPA and made available to state and local agencies and the public. EPA has

developed a web-based submission system, called RMP*eSubmit, that will make filing a RMP or making

changes or corrections to an existing plan easy. You can access this information at

www.epa.gov/emergencies/rmp. EPAs previous system for electronic submission - RMP*Submit -will no longer be available on the EPA website after March 2009.

The RMP includes registration information (basic facility information); the worst-case release scenario; a

five-year accident history (of accidents that caused deaths, injuries, or significant property damage on

site, known offsite deaths or injuries, offsite property or environmental damage, or evacuations or

shelterings in place); emergency response activities; a brief executive summary; and a certification

statement.

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The executive summary should be a brief description of the facility, the worst-case release scenario, steps

you take to prevent accidents (e.g., complying with state and local laws), emergency response

information (e.g., your coordination with the fire department), and any steps you are planning to take to

improve safety (e.g., upgrading equipment to meet newer editions of NFPA-58). The rest of the RMP is

filling in names, addresses, and numbers, and checking appropriate boxes. You do not need to submit

supporting documentation; you need only keep it onsite for inspection. Most propane storage facilities

will not have any accidents to report on the five-year accident history. If you do not, you need not

complete that section. A sample RMP for a Program 1 propane facility is attached.

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PROGRAM 3

If your process is not eligible for Program 1, the process is most likely in Program 3 because it is

probably subject to the OSHA PSM standard. Most propane storage facilities that are in commercial or

industrial areas or close to residential areas will be subject to Program 3.

WHAT MUST I DO FOR PROGRAM 3?

For Program 3, you must:

Analyze both a worst-case release scenario and an alternative release scenario;

Implement a prevention program;

Implement an emergency response program if your employees will respond to a release; and

File an RMP.

WHAT ARE THE RELEASE SCENARIOS?

Worst-Case Scenario.Part 68 defines the worst-case release scenario you must analyze. It is described

in the previous section of this guidance (regarding Program 1). You can simply use Table 2 or

RMP*Comp to define the distance to the 1 psi endpoint for your largest tank.

Alternative Release Scenario. An alternative release scenario is a scenario that is more likely to

happen. It must reach an endpoint offsite unless no such scenario exists. One of the following scenarios

may be appropriate for you.

Pull-Away Explosion. An alternative scenario may be a hose rupture caused by a pull-away. A

pull-away can occur if the driver fails to remove the hoses between the storage tank and the

transfer vehicle before moving the vehicle. In this scenario, the failure involves a 25-foot length

of unloading hose, 4" in diameter. The active mitigation devices are assumed to work as

designed, limiting the release to the contents of the hose. The release leads to a vapor cloud

explosion (endpoint 1 psi). The quantity released is 69 pounds. The distance to the endpoint is

175 feet (report as 0.03 miles).

Piping Break. Another alternative scenario you may want to consider is a break in propane

piping leading to a 10-minute release and explosion. The distance to the 1 psi endpoint is shown

in Table 3.

Appendix B includes release calculations for alternative scenarios as well as scenarios in addition to the

two provided above.

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TABLE 3

DISTANCES TO 1 PSI FOR PIPE RELEASES

Pipe Size (inches) Quantity Released (pounds) Distance to 1 psi

0.5 4,738 0.11 18,951 0.2

2 75,804 0.3

You must estimate in the RMP residential populations within the circles defined by the endpoints for your

worst-case and alternative release scenarios (i.e., the center of the circle is the point of release and the

radius is the distance to the endpoint). You may use Census data and round to two significant digits (e.g.,

1147 becomes 1100, and 123 becomes 120). You do not need to conduct surveys or correct Census data.

In addition, you must report in the RMP whether certain types of public receptors (e.g., schools, hospitals)

and environmental receptors are within the circle. You do not need to identify specific receptors; you

simply need to check off the category.

WHAT DO I HAVE TO DO FOR THE PREVENTION PROGRAM?

The Program 3 prevention program is identical to the OSHA PSM Standard and has 12 elements:

Safety information

Process Hazard Analysis

Operating procedures

Training

Mechanical Integrity (Maintenance)

Pre-startup reviews

Management of change

Compliance audits Incident investigation

Employee participation

Hot work permit

Contractors

If you are complying with NFPA-58 or state or local laws based on it, following the guidelines in the

National Propane Gas Association (NPGA) LP Gas Safety Handbook, and implementing NPGA safety

bulletins, you are probably already doing most of what you need to do to comply with these requirements.

The following sections provide additional information on how your current practices will help you

comply with the EPA rule. For a more complete discussion of the requirements, see the General

Guidance for Risk Management Programs, available at www.epa.gov/emergencies/rmp, and OSHAs

Process Safety Management Guidelines for Compliance (OSHA 3133).

Safety Information. You must have up-to-date information on propane and your propane equipment.

You must have a Material Safety Data Sheet (MSDS) on propane. If you do not have one, contact your

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supplier for a copy. You must also document your maximum intended inventory for your propane

equipment. This will generally be the capacity of your tank or tanks; see Table 1.

You need information on safe upper and lower temperatures, pressures, flows, and compositions. The

following information should meet this requirement:

Propane is a gas at normal temperatures and pressures. It is commonly liquefied by storing it in a

closed container at pressures higher than its equilibrium vapor pressure. There is a direct

relationship between ambient temperature and the pressure inside the storage container. As the

ambient temperature increases, the pressure of the container increases proportionately.

According to NFPA 58, 1998 Edition, Table B-1.2.1, commercial propane when heated to a

temperature of 105 F will produce a pressure of 210 pounds per square inch, gauge (psig).

NFPA 58, 1998 Edition, Table 2-2.2.2 sets the current minimum design pressure for an ASME

tank at 250 pounds per square inch, absolute (psia). This design allows for a maximum vapor

pressure of 215 psia at 100 F. The discharge piping for pumps and compressors is currently

designed to 350 psi and vapor piping is designed for 250 psi according to NFPA 58, 1998

Edition, 3-2.10.2. The minimum temperatures are determined by the steel used in the design of

the storage tank and the piping. Liquid propane (if released at atmospheric pressure) can

refrigerate steel pipes and tanks down to temperatures of -44 F.

Another property of propane in its liquid form is its ability to greatly expand when heated.

Therefore, NFPA 58, 1998 Edition sets the maximum filling capacity of large tanks in Table 4

4.2.2(b) to avoid overfilling.

You must maintain equipment specifications for all equipment that is part of a covered process, including

your bulk storage tank(s), piping, pressure relief valves, hydrostatic relief valves, emergency shutoff

valves, temperature, pressure and level gauges, valves, pumps, compressors, and hoses. Specifications

for your bulk propane storage tank(s) are provided on the nameplate attached to the tank. If you do nothave the information, obtain it from your vendor and keep all such information on file.

You must document the codes and standards you used to design and build your propane facility and that

you follow to operate it. These codes will probably include the electrical and building codes that you

must comply with under state or local laws. Your equipment vendors will be able to provide you with

information on the codes they comply with for their products.

The equipment specifications and lists of standards and codes will probably ensure that your process is

designed in compliance with recognized and generally good engineering practices.

See the EPA and OSHA guidance documents cited above for more information on the elements that must

be documented as part of your safety information.

Process Hazard Analysis. You are required to conduct a process hazard analysis (PHA) to identify the

hazards associated with your equipment and propane, the possible malfunctions of equipment or human

errors that could cause a release, the safeguards needed to control hazards or prevent malfunctions or

errors, and any steps needed to detect or monitor releases. If you are required to comply with NFPA-58,

your review can focus on whether you are in compliance with that standard. You may need to consider

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external events as well as internal failures. If you are in an area subject to earthquakes, hurricanes, or

floods, you should examine whether your system would survive these natural events without releasing

propane. You should consider the potential impacts of lightning strikes and power failures. If your

equipment could be hit by vehicles, you should examine the consequences of that. If you have anything

near the process that could burn, ask yourself what would happen if the fire affected the propane tanks or

equipment. See the EPA and OSHA guidance documents cited above for more information on analysis

techniques and issues to be considered. Appendix C provides a checklist that you can use.

When you complete the review, you must document the results and ensure and document that any

problems are addressed in a timely manner.

Operating Procedures. Written operating procedures describe the tasks you or your operators must

perform, safe process operating parameters that must be maintained, and safety precautions for

operations and maintenance activities. These procedures tell you or your employees how to work safely

every day. Applicable portions of the National Propane Gas Association (NPGA) Certified Employee

Training Program and compliance with certain NPGA Safety Bulletins can be used to meet this

requirement. Other programs may be available that will also be acceptable. See the EPA and OSHA

guidance documents cited above for more information on the elements that must be included in the

procedures. A list of NPGA documents that may meet these requirements is included in Appendix C.

Training. You must ensure that any employee presently operating a process and any employee newly

assigned to a covered process have been trained or tested competent in the operating procedures that

pertain to their duties. For those employees already operating a process on June 21, 1999, you may

certify in writing that the employee has the required knowledge, skills, and abilities to safely carry out

the duties and responsibilities as provided in the operating procedures. You are not required to provide a

specific amount or type of training. You should develop a training approach that works for you. The

NPGAs Certified Employee Training Program and any training you do to meet DOT requirements may

satisfy this requirement. You must provide refresher training. You must determine the frequency ofrefresher training in consultation with any affected employees, but you must provide refresher training at

least once every three years. Training must be documented.

Maintenance. You must prepare and implement procedures to maintain the on-going mechanical

integrity of your propane equipment. You may use procedures or instructions provided by equipment

vendors or procedures in Federal or state regulations or industry codes as the basis for maintenance

procedures. You must also train maintenance workers in these procedures (if a contractor maintains your

equipment, the contractors employees should be trained as well). NPGAs Certified Employee Training

Program covers many of the maintenance procedures for your propane equipment.

You must establish a schedule for inspecting and testing equipment associated with your propane storage

facility. You may obtain recommendations from manufacturers, vendors, or trade associations. Youshould, however, use your own experience as a basis for examining any schedules you obtain from

others. Many things may affect whether a schedule is appropriate. The manufacturer may assume a

constant rate of use. If your actual rate of use (e.g., the amount of propane pumped per hour) varies

considerably, the variations may cause additional wear on the equipment. Extreme weather conditions

may also increase wear on equipment.

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If you have workers that use your propane facility, talk with them as you prepare or adopt these

procedures and schedules. If their experience indicates that equipment fails more frequently than the

manufacturer expects, you should adjust the inspection schedule to reflect that experience.

See the EPA and OSHA guidance documents cited above for more information on these requirements.

A list of NPGA training that applies to maintenance procedures and a maintenance inspection checklist

are included in Appendix C.

Management of Change. You must prepare and implement procedures to manage changes, except

replacements in kind. The purpose of this requirement is to ensure that changes you make do not create

any new hazards and that your employees and contractors are informed of the changes and trained in any

new procedures that are needed prior to start-up. See the EPA and OSHA guidance documents cited

above for more information on these requirements.

Pre-Startup Review. Whenever you install a new covered process or modify an existing one, you must

perform a pre-startup review to ensure that the equipment is in accordance with the design specifications,that all procedures related to the equipment are up-to-date, and that employees have been trained in the

operation of the new or modified process. See the EPA and OSHA guidance documents cited above for

more information on these requirements.

Compliance Audits. At least every three years, you must certify that you have evaluated compliance

with EPAs requirements for the prevention program for each covered process. At least one person who

conducts the audit must be knowledgeable about the process. You must develop a report of the audits

findings, determine and document an appropriate response to each finding, and document that you have

corrected all deficiencies. You must retain compliance audit reports for five years.

Incident Investigation. You must investigate each incident that resulted in, or could have resulted in, a

catastrophic release of propane. A catastrophic release is one that presents an imminent andsubstantial endangerment to public health and the environment. You must start the investigation no later

than 48 hours after the accident. You must create a report on the accident that includes, at least, the date

of the accident and the date the investigation began, a description of the accident, the factors that

contributed to the accident, and any recommendations that resulted from the investigation. You must

address the recommendations and share the findings with any employees whose jobs are affected by the

findings. Investigation reports must be retained for five years.

The NPGA LP-Gas Safety Handbook, and NPGA bulletin #202-93 After Accident Procedure may

help you comply with this requirement.

Employee Participation. You must develop a written plan to implement the requirements for employee

participation. See the OSHA guidance document cited above for more information on this requirement.

Hot Work Permit. You must issue hot work permits for hot work conducted near your covered process.

See the OSHA guidance document cited above for more information on this requirement.

Contractors. If you use contractors to perform maintenance, renovation, or specialty work on or near a

covered process, you must implement a program to ensure that your contractors are qualified to perform

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the work and are informed of the potential hazards. See the OSHA guidance document cited above for

more information on these requirements.

Table 4 summarizes the ways that propane facilities can comply with some of these requirements.

TABLE 4

WAYS TO COMPLY WITH SOME PREVENTION ELEMENTS

Program 3 Prevention Element How a Propane Facility Can Meet This Requirement

Safety Information - Maintain Material Safety Data Sheets on propane

- Use the information provided in this guidance

- Document NFPA-58 information

- Maintain propane equipment vendor-supplied information

- Maintain records on electrical and building codes followed

Hazard Review - Use checklist in Appendix C

- Review compliance with NFPA-58

Operating Procedures - Implement NPGA Certified Employee Training Program

- Comply with NFPA-58

- Comply with NPGA safety bulletins

- Use written operating procedures for propane systems

Training - Implement NPGA Certified Employee Training Program.

- Document training done to meet DOT requirements

- Document training done to comply with NFPA-58

- Comply with NPGA Safety Bulletins

- Provide refresher training at least every three years

Maintenance - Implement NPGA Certified Employee Training Program

- Use checklist in Appendix C

- Establish a maintenance and testing schedule

- Document inspections and maintenance done by equipment

vendors

Compliance Audits - Conduct and document a compliance audit every three years;

respond to each finding, and document that you have corrected

any deficiencies.

Incident Investigation - Implement practices in NPGAs LP-Gas Safety Handbook

- Implement NPGA bulletin #202-93 After Accident Procedure

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WHAT DO I HAVE TO DO FOR THE EMERGENCY RESPONSE PROGRAM?

If you have at least one Program 3 process at your facility, you may be required to implement an

emergency response program, consisting of an emergency response plan, emergency response equipment

procedures, employee training, and procedures to ensure the program is up-to-date. This requirement

applies if your employees will respond to some releases involving propane. The emergency response

section of EPA's rule allows you to decide first whether the employees will respond to an accidental

release of propane and then what involvement the employees will have in the event of a release of

propane. If you choose not to have employees respond, then you must coordinate response actions with

the local fire department and have in place appropriate mechanisms to notify emergency responders when

there is a need for a response.

Some propane storage facilities will rely on local responders to handle any accident. If you plan to have

your employees respond to a propane release, you should consult EPAs General Guidance for Risk

Management Programsto determine what you need to do to develop and implement an emergency

response program.

WHAT DO I HAVE TO DO FOR MY RMP?

The RMP for a Program 3 process will include the same sections covered in the Program 1 process, plus

a report on the alternative release scenario and the report on the prevention program. Except for the

executive summary, the RMP consists of names, numbers, and check-off boxes. If you have more than

one process, you still file only one RMP. If you have multiple Program 3 processes, but they all contain

propane, you report only one worst-case scenario and one alternative scenario to cover all of them. (If

you have multiple Program 1 processes, you must report a worst-case scenario for each Program 1

process to establish that the process is eligible for Program 1.)

If you have one Program 3 process, your RMP will include:

The executive summary (covering the alternative release scenario as well as worst-case)

Registration data

Worst-case and alternative release data

Five-year accident history (only if youve had any accidents to report)

Prevention program data

Emergency response data

The certification

A sample RMP and certification statement for a Program 3 propane facility is attached.

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SAMPLE RMP for PROGRAM 1 PROPANE STORAGE FACILITY(This sample RMP is for a fictitious facility named, Smith Gas Company Terminal.

Any resemblance to any actual facility is accidental).

CERTIFICATION STATEMENT

Based on the criteria in 40 CFR 68.10, the distance to the specified endpoint for the worst-case accidental releasescenario for the following processes is less than the distance to the nearest public receptor:

Wholesale LPG facility

Within the past five years, the process has had no accidental release that caused offsite impacts provided in the riskmanagement program rule (40 CFR 68.10(b)(1)). No additional measures are necessary to prevent offsite impactsfrom accidental releases. In the event of fire, explosion, or a release of a regulated substance from the process,entry within the distance to the specified endpoint may pose a danger to public emergency responders. Therefore,

public emergency responders should not enter this area except as arranged with the emergency contact indicated in

the RMP. The undersigned certifies that, to the best of my knowledge, information, and belief, formed afterreasonable inquiry, the information submitted is true, accurate, and complete.

William R. Smith William R. SmithSignature Print Name

Company Owner 6/21/99Title Date

EXECUTIVE SUMMARY

The accidental release prevention and emergency response policies at your facility: This facility complies withNFPA-58 requirements for LP-Gas storage, and it is our policy to adhere to all applicable federal, state, and locallaws. If an emergency were to occur, it is our policy to notify the Garvin County Fire Department and request thatthey respond to the emergency.

A description of your facility and the regulated substances handled. This facility wholesales LPG, supplyingretail outlets, primarily gas stations and cylinder filling operations at cooperatives. The facility consists of a single18,000-gallon tank, which we fill to between 85% and 88% capacity.

The worst-case release scenario. Our worst-case scenario is failure of the 18,000-gallon storage tank when filledto the greatest amount allowed (88% at 60F), resulting in a vapor cloud explosion. Since this facility is located in arelatively remote, unoccupied area, the worst-case scenario would not affect anyone beyond our property.

The general accidental release prevention program and chemical-specific prevention steps. This facilitycomplies with EPAs accident prevention rule and all applicable state and local codes and regulations. The propane

system is designed, installed, and maintained in accordance with NFPA-58 and state law.

Five-year accident history. We have never had an accident involving propane that caused deaths, injuries, propertyor environmental damage, evacuations, or shelterings in place.

The emergency response program. In the event of an emergency involving our propane system, it is our policy tonotify the Garvin County Fire Department and request that they respond to the emergency. We have discussed this

policy with the fire department; members of the fire department have inspected our propane system.

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b. Title: Company owner

1.8. Emergency Contact

a. Name:William R. Smith


c. Phone: (555) 555-5555

d. 24-hour phone: (555) 555-1111 e. Ext. or PIN:

1.9. Other Points of Contact (Optional)

a. Facility or parent company e-mail address:

b. Facility public contact phone: (555) 555-5555

c. Facility or parent company www homepage address:

1.10. LEPC (Optional): Garvin County LEPC

1.11. Number of full-time employees (FTEs) On Site: 1

1.12. Covered by (select all that apply)

a. OSHA PSM: Yes

b. EPCRA section 302:

c. CAA Title V Air Operating Permit ID:

1.13. OSHA Star or Merit Ranking: No

1.14. Last Safety Inspection Date: 12/07/97

1.15. Last Safety Inspection Performed by (select one) Fire department

1.16. Will this RMP involve Predictive Filing? No

1.17. Process Specific Information. For each covered process fill in the following chart. Use a separate sheet foreach process.

Process Number: 1(optional to help youtrack)

Process Description: Storage tank

(optional to help youtrack)

a. Program Level: 1

b. NAICS Code(s): 42272

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c. Chemical c.1. Name:

Propane

c.2. CAS Number:

74-98-6

c.3. Quantity (lbs.):

67,000

4. FLAMMABLES: WORST CASE

4.1. Chemical Name

4.2. Results based on (select one)

Propane

c. EPAs RMP Guidance for Propane Storage FacilitiesReference Tables or Equations

4.3. Scenario: Vapor Cloud Explosion

4.4. Quantity released (lbs.) 67,000 pounds

4.5. Endpoint Used: 1 psi

4.6. Distance to endpoint (miles) 0.30 miles

4.7. Residential population within distance to endpoint 0

4.8. Public receptors within distance to endpoint (select all that apply)

a. Schools d. Prisons /Correctional facilities

b. Residences e. Recreation areas

c. Hospitals f. Commercial/industrial areas

4.9. Environmental receptors within distance to endpoint (select all that apply)

a. National or state parks, forests, or monuments

b. Officially designated wildlife sanctuaries, preserves, or refuges

c. Federal wilderness area

4.10. Passive mitigation considered (select all that apply)

a. Dikes

b. Fire walls

c. Blast walls

d. Enclosures

e. Other (specify)

4.11. Graphics file name (Optional)

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9. EMERGENCY RESPONSE

9.1. Emergency response (ER) plan

a. Is facility included in the written community emergency response plan? No

b. Does facility have its own written emergency response plan? No

9.2. Does facility ER plan include specific actions to be taken in response to accidental releases of regulated

substance(s)?

9.3. Does facility ER plan include procedures for informing public and local agencies responding to accidental

release?

9.4. Does facility ER plan include information on emergency health care?

9.5. Date of most recent review/update of facility ER plan

9.6. Date of most recent emergency response training for facilitys employees

9.7. Local agency with which the facility ER plan or response activities are coordinated

a. Name of agency Garvin County Fire Department

b. Phone number (555) 555-1000

9.8. Subject to (select all that apply)

9.8.a. OSHA 1910.38

9.8.b. OSHA 1910.120

9.8.c. Clean Water Act/SPCC

9.8.d. RCRA

9.8.e. OPA-90

9.8.f. State EPCRA rules/law

9.8.g. Other (specify)

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SAMPLE RMP for PROGRAM 3 PROPANE STORAGE FACILITY

(This sample RMP is for a fictitious facility named Maryland LPG.Any resemblance to any actual facility is accidental).

CERTIFICATION STATEMENT

To the best of the undersigneds knowledge, information, and belief formed after reasonable inquiry, theinformation submitted is true, accurate, and complete.

Mary L. JonesSignature

Mary L. JonesPrint Name

Company OwnerTitle

6/21/99Date

EXECUTIVE SUMMARY

The accidental release prevention and emergency response policies at your facility: This facility complies withNFPA-58 requirements for LP-Gas storage, and it is our policy to adhere to all applicable federal, state, andlocal laws. If an emergency were to occur, it is our policy to notify the Howard County Fire Department andrequest that they respond to the emergency. We also maintain a fire brigade on site to handle small emergencies.

A description of your facility and the regulated substances handled. This facility is a bulk terminal storingLPG for resale to retail propane outlets. The facility consists of four 30,000-gallon tanks and two 120,000gallon tanks.

The worst-case and alternative release scenarios. Our worst-case scenario is failure of one 120,000-gallonstorage tank when filled to the greatest amount allowed (88% at 60F), resulting in a vapor cloud explosion. Theresulting distance to the endpoint extends offsite, and public receptors are within the distance to the endpoint.Our alternative release scenario is a break in a 0.5-inch diameter pipe, leading to a 10-minute release andexplosion. The resulting distance to the endpoint extends offsite, and public receptors are within the distance tothe endpoint.

The general accidental release prevention program and chemical-specific prevention steps. This facilitycomplies with EPAs accident prevention rule, the OSHA PSM standard, and all applicable state and local codesand regulations. The propane system is designed, installed, and maintained in accordance with NFPA-58 andstate law.

Five-year accident history. We have never had an accident involving propane that caused deaths, injuries,property or environmental damage, evacuations, or shelterings in place.

The emergency response program. In the event of an emergency involving our propane system, it is our policyto notify the Howard County Fire Department and request that they help respond to the emergency. We also

have a trained fire brigade. We have coordinated our response plans with the fire department; members of thefire department have inspected our propane system and conducted a joint exercise with us.

Planned changes to improve safety. None.

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1. REGISTRATION

1.1 Source Identification

a. Facility Name: Maryland LPG

b. Parent Company #1 Name: N/A

c. Parent Company #2 Name:

1.2. RMP Facility Identifier: [EPA will assign]

1.3. EPA Identifier:

1.4. Dun and Bradstreet Numbers (DUNS) N/A

a. Facility DUNS:

b. Parent Company #1 DUNS:

c. Parent Company #2 DUNS:

1.5 Facility Location Address

a. Street 238 Main Street

b. Street - Line 2:

c. City: Odenton d. State: MD e. Zip Code: 21873 f. County: Howard

g. Facility Latitude (degrees, minutes, and seconds): 39 11 15

h. Facility Longitude (degrees, minutes, and seconds): -076 50 10

i. Method for determining Lat/Long : I1 (interpolation, map)

j. Description of location identified by Lat/Long : AB Administrative Building

1.6 Owner/Operator

a. Name: Mary L. Jones

b. Phone: (410) 777-1234

Mailing Address:

c. Street 1: 238 Main St.

e. City: Odenton f. State: MD g. Zip: 21873

1.7. Name and title of person responsible for RMP (part 68) implementation

a. Mary L. Jones

b. Company Owner

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1.8. Emergency Contact

a. Name: Mary L. Jones


c. Phone: (410) 777-1234

d. 24-hour phone: (410) 777-4321 e. Ext. or PIN:

1.9. Other Points of Contact (Optional)

a. Facility or parent company e-mail address:

b. Facility public contact phone: (410) 777-1234

c. Facility or parent company www homepage address:

1.10. LEPC (Optional): Howard County LEPC

1.11. Number of full-time employees (FTEs) On Site: 6

1.12. Covered by (select all that apply)

a. OSHA PSM: Yes

b. EPCRA section 302:

c. CAA Title V Air Operating Permit ID:

1.13. OSHA Star or Merit Ranking: No

1.14. Last Safety Inspection Date: 10/19/98

1.15. Last Safety Inspection Performed by (select one) Fire department

1.16. Will this RMP involve Predictive Filing? No

1.17. Process Specific Information. For each covered process fill in the following chart. Use a separate sheet foreach process.

Process Number: 1(optional to help youtrack)

Process Description: Storage Tanks

(optional to help you

track)

a. Program Level: 3

b. NAICS Code(s): 42271 Petroleum Bulk Terminal

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c. Chemical c.1. Name:

Propane

c.2. CAS Number:

74-98-6

c.3. Quantity (lbs.):

1,331,000

4. FLAMMABLES: WORST CASE

4.1. Chemical Name

4.2. Results based on (select one)

Propane

c. EPAs RMP Guidance for Propane Storage FacilitiesReference Tables or Equations

4.3. Scenario: Vapor Cloud Explosion

4.4. Quantity released (lbs.) 120,000 pounds

4.5. Endpoint Used: 1 psi

4.6. Distance to endpoint (miles) 0.60 miles

4.7. Residential population within distance to endpoint 200

4.8. Public receptors within distance to endpoint (select all that apply)

a. Schools d. Prisons /Correctional facilities

b. Residences

e. Recreation areas

c. Hospitals

f. Commercial/industrial areas

4.9. Environmental receptors within distance to endpoint (select all that apply)

a. National or state parks, forests, or monuments

b. Officially designated wildlife sanctuaries, preserves, or refuges

c. Federal wilderness area

4.10. Passive mitigation considered (select all that apply)

a. Dikes

b. Fire walls

c. Blast walls

d. Enclosures

e. Other (specify)


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7. PREVENTION PROGRAM - PROGRAM 3

For each process or process unit:

7.1. NAICS Code for process: 42271

Propane7.2. Chemical name(s):

7.3. Safety information

Date of most recent review/revision of safety information 02/04/97

7.4. Hazard review

a.1 Date of completion of most recent PHA/update 02/04/98

a.2 Technique used Checklist

b. Expected date of completion of any changes resulting from the PHA 02/04/98

c. Major hazards identified (select at least one)

Toxic release Overpressurization Earthquake

Fire

Corrosion Floods

Explosion

Overfilling

Tornado

Runaway reaction Contamination Hurricanes

Polymerization Equipment Failure Other

Loss of cooling, heating, electricity, instrument air

7.4.d. Process controls in use (select at least one)

Vents Emergency air supply

Relief valves

Emergency power

Check valves Backup pump

Scrubbers Grounding equipment

Flares Inhibitor addition

Manual shutoffs

Rupture disks

Automatic shutoffs

Excess flow device

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7.7. Maintenance

a. Date of most recent review/revision of maintenance procedures 04/01/97

b. Date of most recent equipment inspection/test 10/19/98

c. What equipment inspected/tested Propane tanks, valves, and piping

7.8 Management of Change

a.

Date of the most recent change that triggered management of change procedure:

b. Date of the most recent review or revision of management of change procedures: 6/14/98

7.9 Pre-Startup Review

The date of the most recent pre-startup review:

7.10. Compliance audits

a. Date of most recent compliance audit

b. Expected date of completion of any changes resulting from the compliance audit

7.11. Incident investigation:

a. Date of most recent incident investigation

b. Expected date of completion of any changes resulting from the investigation

7.12 Employee participation plan

Date of the most recent review or revision of the employee participation plan: 4/16/99

7.12 Hot work permit procedures

Date of the most recent review or revision of the hot work permit procedures: 24/12/97

7.13 Contractor safety procedures

a. Date of the most recent review or revision of the contractor safety procedures: 4/16/99

b. The date of the most recent review or revision of contractor safety performance: 4/16/99

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A-2

To determine whether adjacent, non-interconnected propane tanks constitute a single process,

measure the linear distance between the tanks and compare it to the estimated separation distance in

Table A-1 for tanks of that size and with that degree of confinement. Tanks that are separated by less

than the estimated separation distance in Table A-1 should generally be considered a single processand their quantities added together to determine if the process exceeds the RMP threshold of 10,000

pounds. Individual tanks of propane which are separated by at least the estimated separation distance

in Table A-1 for tanks of that size and with that degree of confinement may generally be considered as

separate processes and thus not subject to the RMP regulation.

The distances provided in the Table above should be treated as estimates. Other methods of

determining separation distances may provide more accurate estimates and you are free to use other

reasonable methods if you choose. Also, the separation distances provided here should be considered

in relation to any unique circumstances at your site, such as topography, the presence of structures and

obstacles, the presence of blast-mitigation features, and other site-specific factors. For example, if

engineered blast-barriers are located between tanks, or if your tanks are underground, smaller

separation distances may be appropriate3. On the other hand, topographical features, such as adepression between two tanks where heavier-than-air propane vapor might collect, may warrant the

use of larger separation distances. Additionally, you should evaluate whether there are potential

events other than vapor cloud explosions that could reasonably be expected to cause multiple tanks to

fail, even at distances larger than those in Table A-1. EPA believes that for most properly designed

outdoor propane installations, such events are extremely unlikely, and that separating tanks by at least

the appropriate distance in Table A-1 is sufficient to establish separate processes. However, you

should evaluate your own circumstances and maintain documentation to support your determination.

Some readers of this guidance may conclude that it will be easier to re-locate one or more of their

propane tanks to conform to the distances provided above rather than taking the steps necessary to

comply with the regulation. This is certainly permitted, and in some cases may be an appropriate risk-

reduction measure. However, when taking such actions, you should be careful to maintain sufficientseparation distances between your propane tanks and nearby buildings, roads, and public receptors.

EPA recommends consulting NFPA-58 or other applicable codes or standards to identify such

distances.

3 NFPA-58 generally recommends against installing fire walls, fences, earth or concrete barriers, and other similar

structures around or over non-refrigerated LP-gas containers. There are some exceptions. For example, the standard permits

such structures to partially enclose LP-gas containers, if the structure is designed in accordance with a sound fire protection

analysis.

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APPENDIX B

RELEASE CALCULATIONS

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APPENDIX B - RELEASE CALCULATIONS

The endpoints that can be considered for the alternative release scenario are explosion damage,

radiant heat effect and lower flammability limit vapor concentration. Review these potential

alternative scenarios and pick one or more that best describes a scenario that is more likely to occur

than the worst-case scenario and that has an endpoint which is beyond your facility boundary. The

following are possible alternative release scenarios that use a vapor cloud explosion and an

overpressure of 1 psi.

PULL-AWAY: (ACTIVE MITIGATION DEVICES PERFORM AS DESIGNED)

An alternative scenario for a propane storage facility may be a hose rupture caused by a pull-away. A

pull-away can occur if the driver fails to remove the hoses between the storage tank and the transfer

vehicle (bobtail or transport) before moving the vehicle. In this case, the analysis considers the failure

of a 25 foot length of unloading hose, 4" in diameter. The active mitigation devices are assumed to

work as designed, limiting the release to the contents of the hose.

Volume of hose = cross sectional area of hose x length of hose

Volume of hose = (4 in / 2)2 1 ft2/ 144 in2 25 ft = 2.182 ft3

Wf= 2.182 ft3 .504 62.37 pounds/ft3 = 68.59 pounds of propane

There are three methods described in EPA's OCA that you can use to determine the distance to the

endpoint for an alternative scenario. Two of those methods are used here as an example.

PULL-AWAY EXPLOSION

You can use equation C-1 from EPA's OCA to calculate the distance exposed to greater than 1 psi

overpressure. This method results in a distance to endpoint of 175 feet and the endpoint is 1 psioverpressure.

D = 17 ( 0.1 Wf HCf/ HCTNT)a

Where,

Wf is the weight of propane in kilograms in the vapor cloud,

Hcf is the heat of combustion of propane from Appendix C of EPA's OCA,

HcTNT is the heat of combustion of TNT from Appendix C of EPA's OCA, and

D is the distance in meters from the explosion where overpressure exceeds 1 psi.

D = 17 (.1 Wf 46333/4680)a= 17 (.1 68.6/2.2046 46333/4680)a= 53.29 meters =

D = 174.8 feet

If you use this scenario as your alternative release scenario, the distance to endpoint is 175 feet and

the endpoint used is 1 psi overpressure.

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B-2

PROCESS PIPING BREAKS

Liquid propane pipe failures: ", 1", 2", 3", 4" and 6". (Causes: liquid expansion [failure of

hydrostatic valves], a pull-away [failure of breakaway devices4

], collision, corrosion.) For long pipes,where the length to diameter ratio is significantly greater than one, flashing (i.e., conversion of

gaseous propane to liquid) in the discharge pipe results in a two-phase release. You can estimate the

amount released from a line shear using the following equation:

)0.5]QR = 0.0853 HA F L / [Vgl (T Cp

Where: QR is the release rate in pounds per minute.

HA is the cross-sectional area of the pipe in square inches.

F is the frictional factor, which is 0.85 for pipe with a length to diameter ratio of 50.

L is the heat of vaporization, which is 426,000 joules per kilogram for propane.

Vgl is the specific volume of gas minus liquid in m3/kg, which is 0.056 for propane.

T is the temperature in Kelvins (assumed to be 298).Cp is the heat capacity, which is 2,400 joules/kilogram/Kelvin for propane.

0.0853 is a units conversion factor.

QR can be calculated using the values in the table below for HA. Now Q (the release quantity) can be

calculated for a 10-minute release, and D (the distance to the endpoint in feet) can be calculated using

equation C-1 from EPAs OCA. Note that Q cannot be larger than the amount of propane contained

in your storage tank (this should be considered especially for 6" pipes).

For a 1" pipe:

QR = 512.5 pounds per minute

Q = QR 10 minutes = 5,125 total pounds released (Q = Wf)

D = 17 ( 0.1 Wf HCf/ HCTNT)a= 17 (0.1 5,125 / 2.2046 46333 / 4680)a= 224

D = 224 meters = 735 feet = 0.1 mile

If you use this scenario as your alternative release scenario, the distance to endpoint is 735 feet (or

about 0.1 mile) and the endpoint used is 1 psi overpressure.

4 See NFPA 58, 1998 Edition, Section 3-9.4.2. A breakaway device is used when dispensing LPG. It is designed so that the

breakaway device fails (instead of the piping or hose) allowing other safety devices to retain the fuel and limit the spill. Failure of the breakaway

device means that the breakage occurs somewhere else rather than at the breakaway device during a pull away, thus negating the effectiveness

of some or all of the other safety devices.

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B-3

TABLE B-1

POTENTIAL DISTANCES TO ENDPOINT FOR PIPE RELEASES

(for 1 psi Overpressure)

Pipe Size (inches) HA (inches2) QR

(pounds/minute)

Q Total Amount

Released after 10

minutes (pounds)

D (Miles)

0.50 0.20 128 1,281 0.1

1 0.79 512 5,125 0.1

2 3.14 2,050 20,499 0.2

3 7.07 4,612 46,122 0.3

4 12.57 8,199 81,995 0.4

6 28.27 18,449 184,488 0.5

OVERFILL STORAGE TANK - RELIEF VALVE LIFTS

A safety relief valve lifts (causes: overpressure or overfilling [failure of your level indicator and

administrative procedures]).

A four-valve multiport relief valve has a flow capacity of 27,750 SCFM/Air at 300 psi with three of

the four valves lifting. Estimate the amount of propane discharged from one port over 5 minutes and

the distance to endpoint if the vapor cloud finds a source of ignition and explodes. The density of air

is 12.39 ft3/lb and the density of propane is 8.66 ft3/lb. To convert SCFM (air)to SCFM (propane)multiply

by 0.808.

The release rate from one port is 27,950 SCFM (air)/ 3 = 9,250 SCFM (air)

Q(propane)= Q(air) 0.808 / 8.66 ft3/lb = 863 lbs/min 5 min = 4,315lbs = 1957.4 kg

D = 17 (0.10 1957.4 46,333/4680)a= 211.9 meters 3.281 ft/meter = 695.2ft / 5280ft/mile =0.13 miles.

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B-4

TABLE B-2

RELIEF VALVE DISCHARGES (FOR 1 PSI OVERPRESSURE)

Relief Valve Size(inches) CapacitySCFM of

Air

Release Rate(lbs/min)

Propane

Duration(min) AmountReleased

(lbs)

Distance toEndpoint

(Miles)

Multiport 2" 9,250 863 5 4,315 0.1

Dual Port 1" 5,250 490 5 2,449 0.08

2" 10,390 969 5 4,847 0.1

1" 6,080 567 5 2,836 0.1

1" 5,280 492 5 2,463 0.1

1 " 3,340 312 5 1,558 0.09

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APPENDIX C

CHECKLISTS AND OTHER DOCUMENTS

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PROCESS SAFETY INFORMATION

Process Safety Information Worksheet: Propane Storage

Item Description

MSDS Propane

Maximum Intended Inventory

Nominal Water Capacity of Largest

Tank

Temperature Upper:

Lower:

Pressure Upper:

Lower:

Flow Rate Loading:Unloading:

Vapor Piping

Liquid Piping

Safety Relief Valves

RV1

RV2

RV3

RV4

Internal Valve

Excess Flow Valve

EFV1

EFV2

EFV3

EFV4

Emergency Shutoff Valve

ESV1

ESV2

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C-2

Item Description

Hydrostatic Relief Valve

HSV1

HSV2

HSV3

HSV4

HSV5

HSV6

Pump 1

Pump 2

Compressor 1

Compressor 2

Vaporizer Type: Sz. Flow:

Strainer

Check valves

Sightflow Indicator

Tank Level Indicator

Tank Temperature Indicator

Tank Pressure Indicators

Other Temperature Indicators

Other Pressure Indicators

Design Codes

State or Local Codes

Piping Design

Tank Design ASME NB# State ID#

Vaporizer Design ASME NB# State ID#

Date of Most Recent Revision Revised By:

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C-3

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C-4

PROPANE STORAGE FACILITY CHECKLIST5,6

Answer the questions below by indicating "Yes", "No" or "N/A" (for not applicable). "No" responses

require further comment and a projected completion date for correcting the deficiency.

Siting Yes/No/NA Comments

1. Does the arrangement of your fixed storage tanks conform

with the minimum distances allowed in Table 3-2.2.2 of

NFPA 58, 1998 Edition?

2. Are your fixed storage tanks separated from any oxygen or

hydrogen storage by the minimum distances given in Table

3-2.2.7(f) of NFPA 58, 1998 Edition?

3. Are your transfer points separated from the exposure

points by the minimum distances given in Table 3-2.3.3 of


Piping, Equipment & Container Appurtenances Yes/No/NA Comments

1. Is your storage facility designed according to ASME

code for pressure vessels?

Fixed Storage Tanks ASME?

Vaporizers ASME?

2. Is the pressure rating of your storage tanks appropriate forthe product in service?

Storage Tanks?

Vaporizers?

3. Is the stored product properly identified?

4. On installations with multiple tanks, are the elevations of

your storage tanks arranged to prevent unintentional

overfilling of the lowest container?

5 Completing the Propane Storage Facility Hazard Review Checklist does not guarantee that your facility is in complete compliance

with NFPA 58, 1998 Edition.

6 The Propane Storage Facility Hazard Review Checklist is based on NFPA 58, 1998 Edition. Over the years, various changes

in NFPA 58 have been made to reduce the probability of a propane release. You should carefully review any change to NFPA 58 since your

facility was constructed and consider appropriate changes to ensure the safety of your facility. Document the actions that you take. You should

be ready to explain any differences between the version of NFPA 58 that you used to construct your facility and the current version.

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C-5


5. On installations with stairways or ladders, are they well

anchored, supported and of slip proof construction?

6. On installations with stairways or ladders, are railings

provided and in good condition?

7. On installations with stairways or ladders, are catwalks

provided so personnel need not walk on any portion of

the container?

8. Is your piping designed according to NFPA 58, 1998

Edition, Section 3-2.10?

Are your pump and compressor discharge and liquid

transfer lines suitable for a working pressure of 350 psi?

Is your vapor piping suitable for a working pressure of

250 psi?

On installations with vaporizers, are your vaporizers

designed according to 2-5.4.2 or 2-5.4.3 or 2-5.4.4 and

2-5.4.5 or 2-5.4.6 or 2-5.4.7 of NFPA 58, 1998

Edition?

9. Is the relief capacity of your pressure relief devices:

For fixed storage tanks, designed according to Sections 2

3.2 and 3-2.5 or 3-2.6 of NFPA 58, 1998 Edition?

On installation with vaporizers, are your vaporizers

designed according to 2-5.4.5 or 2-5.4.6 or 2-5.4.7 of


10. Is the capacity of your pressure relief devices designed

according to 2-3.2 and 3-2.5 or 3-2.6 of NFPA 58, 1998

Edition?

Have your relief devices been tested or replaced every ten

years according to the good practice recommended by

Section E-2.3.2 of NFPA 58, 1998 Edition?

11. Do you have appropriate level gauges, temperature

indicators, and pressure gauges installed on your fixed

ASME storage tanks as specified in 2-3.3.2(b), 2-3.3.3,

2.3.4, 2.3.5 of NFPA 58, 1998 Edition?

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12. Do you have the appropriate hydrostatic relief valves

installed between every section of liquid piping which

can be blocked by manual or automatic valves accordingto 2-4.7 and 3-2.11 of NFPA 58, 1998 Edition?

13. Do you have the appropriate corrosion protection

required by 3-2.14 of NFPA 58, 1998 Edition?

14. On installations with pumps, are they installed according

to 3-2.15.1 of NFPA 58, 1998 Edition?

On installations with automatic bypass valves, are they

installed on the discharge of your pump according to

3.2.15(b)1 and 2-5.2 of NFPA 58, 1998 Edition?

15. On installations with compressors, are they installed

according to 2-5.3 and 3-2.15.2 of NFPA 58, 1998

Edition?

On installations with compressors, is there either an

integral means of preventing liquid from entering the

compressor or a liquid suction protection trap according

to 3-2.15.2(b) of NFPA 58, 1998 Edition?

16. Do your compressor and pump motors conform with 2

5.1.4 of NFPA 58, 1998 Edition?

17. On installations with liquid strainers, are they installed onthe suction of your pump or meter according to 3-2.15.3

and 2-5.5 of NFPA 58, 1998 Edition and capable of being

cleaned?

18. On installations with flexible connections on pumps,

compressors or loading and unloading bulkheads, are they

installed as specified by 2-4.6 of NFPA 58, 1998 Edition?

19. Do you have either excess flow valves, backflow check

valves or internal valves as specified by 2-3.3.3 and 3


20. Do you have container appurtenance protection as

specified in 2-3.7 of NFPA 58, 1998 Edition?

21. Do you have manual valves and emergency shutoff valves

as required by 2-4.5.4, 3-2.10.11, 3-3.3.7 and 3-3.3.8 of


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Human Factors Yes/No/NA Comments

3. Are your operators whose job duties require the use of

the above listed equipment understand the operating

limits of the system in regards to:

Capacity?

Pressure?

Temperature?

Adverse Weather or Natural Conditions?

4. Have your operators been trained in the correct response

to conditions which exceed the operating limits of the

system?

5. Have your operators been trained in their duties for

emergency conditions?

Fire?

LP Gas Release?

Severe Weather or Natural Conditions?

6. Are the written operating instructions available to the

operators (see 68.52 of this model program)?

7. Do the written operating instructions reflect current

operation of the facility (see 68.52 of this model

program)?

8. Have major modifications to your propane storage facility

taken place (see 68.48 of this model program)?

9. Are contractors used at the facility?

10. Are safe work practices such as lock/tag, hot work and

line opening followed at the facility?

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Human Factors Yes/No/NA Comments

11. Is there a written emergency response plan (see Subpart E

of this model program)?

Is it current?

Have your operators been trained?

Do you provide emergency response equipment?

Has it been checked?

General Hazards Yes/No/NA Comments

1. Does your propane storage facility have protection

against tampering as specified in under 3-3.6 of NFPA58, 1998 Edition?

2. Does your propane storage facility have lighting as

specified in 3-3.7 of NFPA 58, 1998 Edition?

3. Is the area around your containers and transfer piping free

of all combustible material?

4. Has a fire safety analysis been performed for your

propane storage facility as suggested by 3-10.2.2 and 3


5. Has your fire safety analysis been reviewed by your localfire authority?

6. Has your facility been required by your local fire

authority to provide special protection?

Fixed Water Sprays/Monitor Nozzles?

Insulating Coatings?

Mounding/Burial?

Other types?

7. Has a federal, state or local agency or fire authority

required:

Local Gas Detection Monitors?

Perimeter Gas Monitors and Public Alarms?

This Hazard Review was Completed by: On (Date):

The latest date by which all changes resulting from the process hazard review are expected

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to be completed is . .

Date

OPERATING PROCEDURES REQUIREMENTS

Procedure

Requirement

NPGA Certified Employee

Training Program

(CETP)

NPGA Bulletin

(1) Initial Startup: Distribution

Systems

Operations

Preparing Propane Storage

Containers for Installation.

Distribution

Systems

Operations

Identifying Procedures Used to

Pressure Test and Leak Check

New Propane Distribution

Systems.

(2) Normal Operations: Transfer Systems Identifying Propane Pumps andtheir Operation.

Transfer Systems Identifying Parts and Devices

Basic to Compressors.

Plant Operations Filling Propane Storage

Containers.

Plant Operations Unloading a Propane

Transport.

Plant Operations Unloading a Propane Tank

Car.

Propane Delivery Filling Cargo Tanks on BulkDelivery Vehicles.

(3) Temporary

Operations:

Plant Operations Removing Propane from

Stationary ASME Tanks and

DOT Cylinders.

(4) Emergency Shutdown

and Operation:

200-89 How to Control LP-Gas

Leaks & Fires

202-81 What you should do in

case of accidents

involving LP-Gas

202-93 Steps to Take in the Event

of an Accident Involving

Propane

204-88 How to Handle LP-Gas

Fires with Portable Fire

Extinguisher

206-91 Emergency Response

Guidelines

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Procedure

Requirement

NPGA Certified Employee

Training Program

(CETP)

NPGA Bulletin

207-94 Guidelines for Developing

Plant Emergency

Procedures

211-91 LP-Gas Fire Control and

HAZ MAT Training

Guide

(5) Normal(Manual)

Shutdown:

(6) Startup following a

normal or emergency

shutdown or a major

change that requiresa hazard review: See

item (1) above.

(7) Consequences of

deviations and steps

required to correct or

avoid deviations.

(8) Equipment

inspections.

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MAINTENANCE TRAINING

Module Certified Employee Training Program (CETP)

Basic Principles Identifying the Proper Use of Personal Protective Equipment

Basic Principles Identifying the Proper Use of Tools and Equipment

Basic Principles Identifying by Sight Hand Tools Commonly Used by Service Technicians

Basic Principles Identifying Pipe/Tube, Pipe/ Fittings, and Associated Tools

Transfer Systems

Operations

Identifying Propane Pumps and Their Operation

Transfer Systems

Operations

Identifying the Standards for Sizing, Installing and Inspecting Pump Protective

Devices

Transfer Systems

Operations

Troubleshooting Propane Pumps and Metered Delivery Systems

Transfer Systems

Operations

Identifying Parts and Devices Basic to Compressors

Transfer Systems

Operations

Maintaining and Troubleshooting Compressors

Distribution Systems Identifying the Operating Characteristics of Propane Vapor Regulators and

Metering Systems

Distribution Systems Installing Propane Vapor Regulating and Metering Systems

Distribution Systems Sizing Pipe for Use in Low Pressure Propane Distribution Systems

Distribution Systems Identifying Steel/Wrought Iron Piping Materials and Installing Procedures

Distribution Systems Identifying Tubing Materials and Installing Procedures

Distribution Systems Identifying and Sizing Vaporizer Systems

Distribution Systems Sizing Propane Liquid Piping Systems

Distribution Systems Identifying Installing and Servicing Procedures for Vaporizer Systems

Plant Operations Identifying the Operating Characteristics of Pressure Relief Valves

Plant Operations Identifying and Installing Gauges in Propane Storage Containers

Plant Operations Identifying the Operating Characteristics of Check Valves

Plant Operations Identifying the Operating Characteristics of Service Valves

Plant Operations Installing Valves in Propane

Plant Operations Inspecting Servicing and Maintaining Container Valves

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Module Certified Employee Training Program (CETP)

Transfer Systems

Operations

Identifying the Operation and Maintenance of Withdrawal Valves

Transfer Systems

Operation

Identifying the Operation and Maintenance of Bulkheads and Emergency Shutoff

Valves (ESVs)

Distribution Systems

Operations

Installing Propane Liquid Distribution and Vaporizer Systems

Transfer Systems

Operation

Identifying the Operation and Maintenance of Hoses, Hose End Valves, and Hose

Reels


Operations

Identifying the Causes of Corrosion on Metal Surfaces


Operations

Identifying Methods and Procedures Used to Protect Metal Structures from

Corrosion


Operations

Identifying Procedures Basic to Installing Anodes and Testing Cathodic Protection

Systems


Operations

Identifying Procedures Used to Pressure Test and Leak Check New Propane


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MAINTENANCE INSPECTION CHECKLIST AND TESTS FOR PROPANE STORAGE

FACILITIES

I. Construction Code Compliance Yes No and Comment

a) Check manufacturers data plate. Is it securely attached

and legible?

For each fixed storage vessel?

On installations with vaporizers, for each vaporizer?

b) Are the data plate(s) free of corrosion?

II. Conditions of Container(s) and Vaporizer(s) and Paint Yes No and Comment

a) Are above-ground containers properly painted?

Fixed storage tanks?

On installations with vaporizers, the vaporizers?

b) Are containers and vaporizers free of corrosion damage,

dents, gouges, or other damage?

III. Foundations Yes No and Comment

a) Are foundations in good condition?

b) Are footings free of settling which might cause

misalignment or piping strain?

c) Are containers and vaporizers free of corrosion at masonry

contact area?

d) Are saddle pads in good condition?

IV. Container Connections Yes No and Comment

a) Have excess flow and back flow check valves been recently

checked for proper operation?

V. Tank Fittings Yes No and Comment

a) Are all ACME (or other type) connectors in good condition

with good gaskets and are they plugged or capped? (See

NPGA Bulletin #134 Care and Inspection of ACMEThreaded Hose Couplings.)

b) Are all unused openings plugged or capped?

c) Are all fittings and hoses leak free?

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and legible?




d) Are there visible signs of exterior corrosion?

XI. Valves (for Fixed Storage Tanks and Vaporizers) Yes No and Comments

a) Are valves in good working order?

b) Do seats shut off tightly?

c) Is packing free of leaks?

d) Are necessary valve handles available at the valve location?

XII. Hydrostatic Relief Valves (for Fixed Storage Tanks and

Vaporizers)

Yes No and Comments

a) Are the valves in good working order and not leaking?

b) Are the valves fitted with protective caps?

c) Are the valve discharges positioned to avoid impinging gas

on the tank?

XII. Transfer Areas Yes No and Comments

a) Are hoses in good condition and free of deterioration, wear,

and blisters? See NPGA Bulletin #114 Guide to Hose

Inspection.

b) Are hoses capped or plugged when not is use?

c) Are hose couplings properly attached and fully seated on

the hose?

d) Are hose couplings worn or damaged?

e) Are coupling gaskets in good condition?

f) Are correct coupling wrenches available?

g) Are excess flow valves operating correctly?

h) Are the loading and unloading risers protected from traffic?

I) Are chock blocks provided for rail cars?

j) Have your fire extinguishers been tested and/or serviced?

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and legible?




k) Is adequate transfer hose storage available?

m) Are the written transfer instructions readily available?

XIV. Pumps and Compressors Yes No and Comments

a) Are the shafts free of leaks?

b) Are pumps equipped with a spring loaded by-pass valve

where required?

c) Is the by-pass valve functioning properly?

d) Are drive belts or couplings protected by suitable guards?

e) Is the compressor crank case oil at the proper level?

XV. Electrical Equipment Yes No and Comments

a) Do all switches, etc. function properly?

b) Are all housings properly assembled to maintain seal?

Inspected By: Inspection Date:

These procedures were last reviewed or inspected by: Date:

Name (signature)

Piece of Equipment Inspected: Most Recent

Date:

Storage Propane

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